Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Model
GP7122
Contents:
Installation Instructions:
Pump Specifications:
Exploded View:
Parts List:
page 2
page 3
page 4
page 5
Kits:
page 6
Torque Specifications:
Repair Instructions:
Dimensions:
page 6
pages 7-10
page 11
back page
Warranty Information:
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Specifications Model GP7122
Volume........................................................................................................ Up to 9.9 GPM
Discharge Pressure ..................................................................................... Up to 10,000 PSI
Speed .......................................................................................................... Up to 750 RPM
Inlet Pressure .............................................................................................. Up to 90 PSI1
Plunger Diameter........................................................................................ 22mm
Plunger Stroke ............................................................................................ 48mm
Crankshaft Diameter................................................................................... 48mm
Key Width................................................................................................... 14mm
Crankshaft Mounting.................................................................................. Either side
Shaft Rotation................................................................................ Top of pulley towards manifold
Temperature of Pumped Fluids .................................................................. Up to 140 oF
Inlet Ports ................................................................................................... (2) 1 1/4" BSP2
Discharge Ports........................................................................................... (2) 3/4" BSP3
Weight......................................................................................................... 374 lbs.
Crankcase Oil Capacity .............................................................................. 1.6 Gal.
Fluid End Material ..................................................................................... Stainless Steel
Volumetric Efficiency @ 750 RPM............................................................ 89%
Mechanical Efficiency @ 750 RPM........................................................... 83%
Consult the factory for special requirements that must be met if the pump is to
operate beyond one or more of the limits specified above.
1Positive inlet pressures are recommended!
2To convert to FNPT threads, add 13377-0100 (Adapter) and 13376-0100 (Seal)
3To convert to FNPT threads, add 14081-0100 (Adapter) and 14082 (Seal)
System Requirements: No Unloader or Regulator allowed. Must use a safety valve and dump gun.
90
30
26
23
85
80
75
70
750 RPM
500 RPM
0
500
600
RPM
NPSHR Chart
700
0
2900
5800
Pressure (PSI)
8700 11,600
GP7122 HORSEPOWER REQUIREMENTS
RPM GPM 3000 PSI 5000 PSI 6000 PSI 7250 PSI 10000 PSI
90
85
80
75
70
300 4.0
400 5.3
550 7.3
600 7.9
650 8.6
700 9.2
750 9.9
8.6
14.3
18.9
26.1
28.2
30.7
32.9
35.4
17.1
22.7
31.3
33.9
36.9
39.4
42.4
20.7
27.4
37.8
40.9
44.5
47.6
51.3
28.6
37.9
52.1
56.4
61.4
65.7
70.7
11.4
15.6
16.9
18.4
19.7
21.2
0
2900
5800
8700 11,600
Pressure (PSI)
HORSEPOWER RATINGS:
We recommend a 1.1 service factor be specified
when selecting an electric motor as the power source.
The rating shown are the power requirements for the
pump. Gas engine power outputs must be
approximately twice the pump power requirements
shown above.
To compute specific pump horsepower requirements,
use the following formula:
GPM X PSI
= hp
1400
3
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Must be on inlet connection
side. See note on pg. 2.
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GP7122 PARTS LIST
ITEM
1
PART
07600
13000
07601
07602
07603
06225
13133
13134
07606
07182
07607
07608
07184
07610
07611
07612
13405
07614
13182
13183
13184
07619
DESCRIPTION
Crankcase
QTY.
1
ITEM
39B
40
PART
06266
07338
06753
06754
06755
06756
06757
13390
06758
07690
13159
13160
06759
13162
12056
07354
06760
06761
06762
06763
06764
06078
07699
07700
07693
07702
07661
13150
13151
06765
06766
06767
06589
DESCRIPTION
Support Ring
Tension Spring
Support Disc
Spiral Ring (Packing)
Support Ring
Guide Ring
QTY.
6
2
Oil Filler Plug Assembly
Crankcase Cover
Seal for Crankcase Cover
Oil Dip Stick
1
3
4
1
41
3
5
1
42
6
8
1
43
6
9
O-Ring, Dip Stick
Hexagon Screw
Spring Washer
1
44
3
10
12
12
5
45
Pressure Ring
Seal Ring
3
11
46
3
12
Drain Plug
47
Spacer Disc
3
13
Gasket, Drain Plug
Bearing Cover
2
48
Circlip
3
14
2
49
Stud Bolt
8
15
Radial Shaft Seal
O-Ring for Bearing Cover
Taper Roller Bearing
Fitting Disc (Shim)
Shaft Protector
2
49A
50
Hexagon Nut
Valve Casing
Centering Stud
Support Ring
O-Ring
8
16
2
1
20
2
50A
51A
51B
51C
51D
51E
51F
52C
57
2
20A
21
1-5
1
6
6
22
Crankshaft
1
Inlet Valve Seat
Valve Plate
3
23
Key
1
6
24
Connecting Rod Assy.
Crosshead Assy.
Crosshead Pin
3
Valve Spring
Spacer Pipe
6
25
3
6
28
3
Discharge Valve Seat
Tension Spring
Plug
3
30
Cover Plate
1
3
30A
30B
30C
30D
31
07225-0100 Hexagon Screw
8
58
3
13136
07622
13154
07623
07624
07625
07626
07627
07628
13137
06748
06749
22764
06750
06751
06752
07150
Grommet
4
58A
58B
58C
59A
60
O-Ring
3
Disc
8
Support Ring
Hexagon Screw
Copper Ring (Gasket)
Plug 3/4” BSP
Plug 1-1/4” BSP
Connecting Screw
Connection Ring
Seal Ring
3
Cover
1
12
3
Eye Bolt
1
32
Radial Shaft Seal
Seal Ring
3
1
32A
33
3
61
1
Seal Retainer
O-Ring for Seal Retainer
Circlip for Seal Retainer
Oil Scraper (Flinger)
Plunger
3
62
1
33A
33B
34
3
62A
62B
63
1
3
2
3
Plug
1
36
3
64
07258-0100 Steel Ring
2
38
Seal Sleave
Serrated Pin
Leakage Gasket
O-Ring
3
66
13362
13358
06588
06768
06769
07704
Disc for Crankshaft
1
38A
38B
38C
39
3
67
Hexagon Screw
1
3
69
Screw-in Connector
Threaded Elbow
1
3
70
1
Seal Case
3
71
Curved Leakage Pipe
Valve Tool (not shown)
1
39A
O-Ring
6
1
5
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GP7122 REPAIR KITS
Plunger Packing Kit #09551
Inlet ValveAssembly Kit #09552
Item
51A
51B
51C
51D
51E
Part #
12056
07354
06760
06761
06762
Description
Support Ring
O-Ring
Qty.
1
Item
39A
39B
42
Part # Description
07150 O-Ring
Qty.
6
1
06266 Support Ring
06754 Spiral Ring (Packing)
06755 Support Ring
06756 Guide Ring
13390 Seal Ring
6
Inlet Valve Seat
Valve Plate
Valve Spring
3
6
6
43
6
6
44
3
46
3
Discharge ValveAssembly Kit #09553
Item
51A
51B
51D
51E
52C
Part # Description
12056 Support Ring
07354 O-Ring
Qty.
Oil Seal Kit #09225
1
1
1
1
1
Item
Part # Description
Qty.
3
32
07624 Radial Shaft Seal
07625 Seal Ring
07627 O-Ring
06761 Valve Plate
06762 Valve Spring
06764 Discharge Valve Seat
32A
33A
3
3
GP7122 TORQUE SPECIFICATIONS
Position
Item#
13406
13138
13160
07702
Description
Inner Hexagon Screw
Plunger
Torque Amount
24
36
49A
58C
30 (ft.-lbs.)
33 (ft.-lbs.)
103 (ft.-lbs.)
155 (ft.-lbs.)
Nut
Hexagon Screw
6
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GP7122 REPAIR INSTRUCTIONS
NOTE: Always take time to lubricate all metal and non-metal parts with a light film of oil before reassembling. This
step will help ensure proper fit, at the same time protecting the pump non-metal parts (elastomers) from cutting and scoring.
TO CHECK VALVES
58B
58A
57
2) Take plugs (58) out of valve
casing (50) by tightening
screws (58C) against valve
casing with two screws.
3) Remove the compression
spring (57) O-Ring (58A)
and support ring (58B).
1) Lossen and remove screws
(58C) with a 24mm socket
wrench.
51C (Suction)
52C (Discharge)
4) Take out valve assemblies
(52 & 51) using either tool
(part #07704) or a stud bolt.
5) Valve seats (51C and 52C) are pressed out of spacer pipe (51F)
by hitting the valve plate (51D) with a socket extention.
51E
51D
52C
51A
51B
6) Check surfaces of valve plate (51D), valve seat (51C or 52C),
o-rings (51A), and support rings (51B). Replace worn parts.
7
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GP7122 REPAIR INSTRUCTIONS
7) When reassembling: The inlet valve seat (51C) is 1mm smaller in
diameter than the discharge valve seat (52C). Inlet valve seats are
marked "S" and always have to be installed first. Discharge valve
seats are marked "P" and are always to be installed on top of inlet
valve. Plugs (58) are to be tensioned down evenly with screws (58C)
and in crosswise pattern at 155 (ft.lbs.).
Valve Seat identification markings
TO CHECK SEALS
9) With a rubber mallet tap the
back of the valve casing (50)
and pull the valve casing off
the stud bolt (49).
10) Remove cover plate (30)
8) Loosen nuts (49A) with a
24mm socket wrench.
with a 10mm socket wrench.
12) Remove tension spring (40)
from seal retainer (38).
13) Pull seal sleeves (38) and
plungers (36) out of their
fittings in the crankcase
(1) using ring groove as a
guide.
11) By gripping hex flats, sepa-
rate plunger (36) from cross-
head (25) by means of two
open-end wrenches (size
22mm and 27mm).
8
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GP7122 REPAIR INSTRUCTIONS
CAUTION: Don't loosen the 3 plunger (36) before the valve casing has been removed otherwise the
plunger (36) could hit against the spacer pipe (51F) when the pump is being turned.
38A
38
38C
38B
14) Remove circlip ring (48)
from seal sleeve (38). Re-
move spacer disc (47) and
seal ring (46) from seal
sleeve. Replace worn or
damaged parts.
15) Remove leakage gasket (38B) from serrated pin (38A) on the
seal sleave (38). Check o-ring (38C) for damage and replace if
necessary. IMPORTANT! The 3.2 mm (diameter bore of the leak-
age gasket (38B) must be inserted directly on the serated pin (38A)
of the seal sleeve (38). The leakage gasket must fit snugly to the
seal so that the bevelled surface of the gasket faces outwords.
45
44
43
42
43
42
41
16) Remove support disc (41) seal unit (42, 43, 44) and pressure ring
(45) of seal sleeve (38). Examine seals for signs of wear or cavi-
tation, and if necessary, replace.
NOTE: Seal life can be increased if
the pretensioning allows for
a little leakage. This assists
lubrication and keeps the
seals cool. It is therefore
not necessary to replace
seals before the leakage
becomes too heavy and
36
33B
34
44
causes output and operating
pressure to drop.
17) Examine plunger (36) for signs of wear or cavitation. If the
surface of the plunger is worn, screw out the plunger with a
27mm tool. Clean centering and front surface of crosshead
with plunger (25).Thread new plunger carefully through
oiled seals in seal sleave. Coat thread of new plunger lightly
with bonding agent (e.g., loctite).
9
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GP7122 REPAIR INSTRUCTIONS
TO ASSEMBLE VALVE CASING
18. Check O-rings (39A) and
support rings (39B) on seal
case (39). Clean surfaces of
seal sleeves (38) in crankcase
(1) and sealing surfaces of
valve casing (50). Insert seal
sleeve with plunger into
crankcase guide. Turn crank-
shaft to (22) until plunger with
crosshead (25) pushes against
plunger tighten plunger (36) to
26 ft-lbs.
39A
39B
39
39B
39A
19. Push valve casing carefully over O-rings of seal case and centering studs (50A). Tighten nuts (49A) to space
103 ft-lbs.
TO DISASSEMBLE GEAR END
20. Take out plunger (36) and seal sleeves (38) as described above. Drain oil.
21. After removing the circlip ring (33B), pry out seal adapter (33) with a screw driver
22. Check seals (32,32A,33A) and surfaces of plunger base (25).
23. Remove crankcase cover (4). Loosen inner hexagon screws (24A) on the connecting rods (24) and push
con rod halves as far into the crosshead guide as possible.
CAUTION: Connecting rods (24) are marked for identification. Do not twist connecting rod halves.
Connecting rod is to be reinstalled in the same position on crankshaft journals.
24. Check surfaces of the connecting rod (24) and crankshaft (22).
25. Take out bearing cover (14) to one side and push out crankshaft (22) taking particular care that the
connecting rod (24) doesn't bend.
CAUTION: Ring (32A) must always be installed so that the seal-lip on the inside diameter faces the oil.
26. Reassemble in reverse order: Regulate axial bearing clearance - minimum 0.1mm, maximum 0.15mm-by
means of fitting disc (20A). The crankshaft (22) should turn easily with little clearance. Tighten inner
hexagon screws (24A) to 30 ft.-lbs.
CAUTION: Connecting rod (24) has to be able to be slightly moved sidewise at the stroke journals.
27. Reassemble cover (4) and seal (5) onto crankcase (1). Fasten with hexagon screws (10).
28. Reinstall shim (33C), and seal adaptor (33) with radial shaft seal (32), ring (32A) and o-ring (33A) onto
crankcase (1).
29. Reinstall remainder of fluid end as described above in “To Assemble Valve Casing” section (21 and 22
above).
10
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GP7122 Dimensions (Inches)
93
340
330
584
227
300
690
476.5
141.5
59
260
11
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GIANT INDUSTRIES LIMITED WARRANTY
Giant Industries, Inc. pumps and accessories are warranted by the manufacturer to be free from
defects in workmanship and material as follows:
1. For portable pressure washers and car wash applications, the discharge manifolds
will never fail, period. If they ever fail, we will replace them free of charge. Our other
pump parts, used in portable pressure washers and in car wash applications, are
warranted for five years from the date of shipment for all pumps used in NON-SALINE,
clean water applications.
2. One (1) year from the date of shipment for all other Giant industrial and consumer
pumps.
3. Six (6) months from the date of shipment for all rebuilt pumps.
4. Ninety (90) days from the date of shipment for all Giant accessories.
Thiswarrantyislimitedtorepairorreplacementofpumpsandaccessoriesofwhichthe manufacturer’s
evaluation shows were defective at the time of shipment by the manufacturer. The following items
are NOT covered or will void the warranty:
1. Defects caused by negligence or fault of the buyer or third party.
2. Normal wear and tear to standard wear parts.
3. Use of repair parts other than those manufactured or authorized by Giant.
4. Improper use of the product as a component part.
5. Changes or modifications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specifications set forth
in the Operations Manuals provided by Giant Industries, Inc.
Liability under this warranty is on all non-wear parts and limited to the replacement or repair of those
products returned freight prepaid to Giant Industries which are deemed to be defective due to
workmanship or failure of material. A Returned Goods Authorization (R.G.A.) number and completed
warranty evaluation form is required prior to the return to Giant Industries of all products under
warranty consideration. Call (419)-531-4600 or fax (419)-531-6836 to obtain an R.G.A. number.
Repair or replacement of defective products as provided is the sole and exclusive remedy provided
hereunder and the MANUFACTURER SHALL NOT BE LIABLE FOR FURTHER LOSS, DAMAGES,
OR EXPENSES, INCLUDING INCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY OR
INDIRECTLY ARISING FROM THE SALE OR USE OF THIS PRODUCT.
THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR
REPRESENTATION, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WAR-
RANTIESORMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSEANDALLSUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
GIANT INDUSTRIES, INC. 900 N. Westwood Ave., P.O. Box 3187, Toledo, Ohio 43607
9/01 GP7122.PM6
Ó Copyright 2001 Giant Industries, Inc.
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